JP6872908B2 - Integrated smart susceptor heater blanket and vacuum bag deployment system for large composite surface laminate debulk - Google Patents

Description

The teaching relates to the manufacture of laminated composites, including, for example, debulks of uncured composite laminates for forming components for aircraft, aerospace vehicles, or other vehicles.

It is well known that components for vehicles such as aircraft and aerospace vehicles, ground vehicles, etc. are manufactured from fiber sheets. Composite parts containing multiple composite plies or sheets pre-impregnated with uncured resin (ie, prepreg) may be assembled during the layup process. During the layup, several (ie, 20, 40, or more) uncured composite plies are laminated, and then air that can be trapped between each of the several plies is introduced during the "debulk" process. It may also be removed using a vacuum. The resin can then be cured in an oven or autoclave. During curing of the resin, the components are supported by a curing tool that maintains the shape of the components while heat is applied to the components to cure the resin.

Devalking and curing of multiple composite plies can be performed in an autoclave. In addition, techniques have been developed for debulking composite parts without the need for an oven or autoclave. For example, a plurality of uncured composite plies can be placed in a vacuum bag and heated to temperatures below the curing temperature. The vacuum bag is evacuated and air is removed between the adjacent plies. The debulk composite can then be removed from the vacuum bag and processed in the autoclave to prepare for heating to the curing temperature.

Debulking components through the application of heat within a vacuum bag is convenient and cost effective for smaller parts. Relatively small heater blankets can be manufactured at a reasonable cost and used to debulk smaller components. However, this approach may not be suitable for some components such as aircraft components (eg, horizontal stabilizers) that can be manufactured as a large single seamless structure.

Therefore, there is a need for methods and equipment for OOA devaluation of composite parts from autoclaves using relatively simple and inexpensive curing tooling. Also, the above types of methods and equipment are well suited for processing relatively large parts from autoclaves using induction heating and smart susceptors for accurate and uniform temperature control during the debulk process. Is also needed.

The following is a brief overview to provide a basic understanding of some aspects of one or more embodiments of this teaching. This overview is neither an extensive overview nor intended to identify the main or important elements of this teaching or to accurately describe the scope of this disclosure. Rather, the main purpose of this overview is merely to present one or more concepts in a simplified form as a prelude to the detailed description presented later.

In one embodiment, the heater blanket deployment system is a first heater comprising a first smart susceptor heater blanket and a second smart susceptor heater blanket located adjacent to the first smart susceptor heater blanket. A first configured such that during processing of the blanket assembly and the first workpiece, the first smart susceptor heater blanket and the second smart susceptor heater blanket are configured to cover the first working surface. A first workstation with a working surface can be included. The deployment system includes a second heater blanket assembly with a third smart susceptor heater blanket and a fourth smart susceptor heater blanket located adjacent to the third smart susceptor heater blanket, and a second cover. A second working surface comprising a third smart susceptor heater blanket and a second working surface configured such that a fourth smart susceptor heater blanket covers the second working surface during processing of the workpiece. Workstations may be further included. The deployment system includes a frame that supports the first heater blanket assembly and the second heater blanket assembly, and at least one power source configured to power the first and second workstations from the frame. And can be further prepared.

In one embodiment, the frame is configured to allow the first heater blanket assembly to move towards and away from the first working surface, and further, a second heater blanket. The assembly may be configured so that it can be moved towards and away from the second working surface. The frame may further include a first mounting surface coupled to the first heater blanket assembly and a second mounting surface coupled to the second heater blanket assembly. The heater blanket deployment system may be configured such that the first workpiece can be processed in the first workstation only when the second workpiece in the second workstation has not been processed. ..

In one embodiment, the base may be mechanically connected to the first mounting surface and the second mounting surface, the first mounting surface, the second mounting surface and the base having a Y-shaped frame. Form.

The frame is configured to lower the first heater blanket assembly towards the first working surface and raise the first heater blanket assembly away from the first working surface, and further It can be an overhead frame with multiple winches configured to lower the second heater blanket assembly towards the work surface and raise the second heater blanket assembly away from the second work surface.

The heater blanket deployment system may further comprise a plurality of lifting straps attached to one of the first heater blanket assembly and the second heater blanket assembly, with the plurality of winches using the plurality of lifting straps. It is configured to lower the first heater blanket assembly towards one work surface and raise the first heater blanket assembly away from the first work surface, and with multiple lifting straps. The second heater blanket assembly is configured to be lowered towards the second working surface and raised away from the second working surface.

The first workstation may further include a first vacuum bag, the first workstation may be configured such that the first vacuum bag covers the first working surface during the processing of the workpiece. .. The second workstation may further include a second vacuum bag so that the second workstation covers the second working surface during processing of the second workpiece. Can be configured. The frame may further include a base placed directly between the first and second workstations. The heater blanket deployment system may further include a vacuum source in fluid communication with the first and second vacuum bags. The power supply and vacuum supply device can be located within the base of the frame.

The heater blanket deployment system includes at least a first elongated seal configured to maintain a first vacuum between the first heater blanket assembly and the first working surface, and a second heater blanket assembly and a first. It may further include at least a second elongated seal configured to maintain a second vacuum between the two working surfaces.

The heater blanket deployment system may further include a first protective release layer covering the first smart susceptor heater blanket and the second smart susceptor heater blanket. The second protective release layer may cover the third smart susceptor heater blanket and the fourth smart susceptor heater blanket. The first protective release layer is positioned between the first smart susceptor heater blanket and the first working surface, and the second protective release layer is the second smart susceptor heater blanket and the second working surface. Can be placed between.

The first smart susceptor heater blanket includes a first wire assembly that includes a first susceptor wire wound around a first litz wire, and a second smart susceptor heater blanket is around a second litz wire. It may include a second wire assembly that includes a wound second susceptor wire. The first wire ribbon may include a first wire assembly. The first wire ribbon may have a first length from the first connector to the second connector. The second wire ribbon may include a second wire assembly, the second wire ribbon having a second length from the third connector to the fourth connector. The first length can vary by less than ± 20% from the second length.

In another embodiment, the method for processing the first workpiece and the second workpiece is to place the first workpiece on the first working surface of the first workstation. And; a first heater blanket assembly with a first smart susceptor heater blanket, a second smart susceptor heater blanket, and a first vacuum bag from a first position away from the first workpiece. Moving to a second position close to the first workpiece; powering the first smart susceptor heater blanket and the second smart susceptor heater blanket to heat the first workpiece. Can include things. The method is to evacuate the first vacuum bag to remove gas from the first workpiece; the second workpiece is subjected to a second operation on a second workstation. Placed on a surface; a third smart susceptor heater blanket, a fourth smart susceptor heater blanket, and a second heater blanket assembly with a second vacuum bag are separated from the second workpiece. It may further include moving from a third position to a fourth position close to the second workpiece. In addition, the method is to power the third smart susceptor heater blanket and the fourth smart susceptor heater blanket to heat the second workpiece; remove gas from the second workpiece. This may include subjecting the second vacuum bag to a second vacuum process. The first workstation is located adjacent to the second workstation; the first smart susceptor heater blanket, the second smart susceptor heater blanket, the third smart susceptor heater blanket, and the fourth smart susceptor heater. The blanket power supply can be performed using a power source supported by the frame. Evacuation of the first and second evacuation bags can be performed using a vacuum source supported by a frame.

The method is to move the first mounting surface of the frame attached to the first heater blanket assembly during the movement of the first heater blanket assembly; and during the movement of the second heater blanket assembly. It may further include moving the second mounting surface of the frame attached to the heater blanket assembly of 2. The frame is a first only when the first mounting surface and the first heater blanket assembly of the frame move from the second mounting surface and the second heater blanket assembly from the fourth position to the third position. It may be configured to be able to move from position to second position. In one embodiment, the second vacuum bag cannot be evacuated while the first vacuum bag is evacuated. In another embodiment, the frame is first from a first position where the first mounting surface and the first heater blanket assembly of the frame are independent of the movement of the second mounting surface and the second heater blanket assembly. It may be configured to be able to move to position 2. The first workpiece comprises a plurality of first uncured composite plies, the second workpiece comprises a plurality of second uncured composite plies, the method being vacuumed in a first vacuum bag. It may further include devaluing the first workpiece during the process and devaluing the second workpiece during the vacuuming of the second vacuum bag.

The accompanying drawings, which are incorporated into this specification and which form part of this specification, exemplify embodiments of the present teaching and, together with explanatory parts, serve to explain the principles of the present disclosure.

It is a perspective view of the wire assembly including the litz wire and the susceptor wire according to the embodiment of this teaching. FIG. 3 is a perspective view of a wire ribbon including a plurality of wire assemblies according to an embodiment of the present teaching. It is a top view of the smart susceptor heater blanket according to the embodiment of this teaching. FIG. 5 is a plan view showing two or more adjacent smart susceptor heater blankets according to an embodiment of the present teaching. It is the schematic of the processing assembly such as the devaluation apparatus by embodiment of this teaching. It is a schematic plan view which shows a part of the smart susceptor heater blanket by embodiment of this teaching. FIG. 5 is a schematic plan view showing two or more smart susceptor heater blankets connected in series according to an embodiment of the present teaching. FIG. 5 is a schematic plan view showing two or more smart susceptor heater blankets connected in parallel according to the embodiment of the present teaching. FIG. 5 is a plan view showing a plurality of smart susceptor heater blankets and uncured composite parts according to the embodiment of the present teaching. FIG. 5 is a cross-sectional view showing a plurality of smart susceptor heater blankets and uncured composite parts to be debulked according to an embodiment of the present teaching. FIG. 6 is a cross-sectional view of a heater blanket assembly and a composite layer processed within the heater blanket assembly. It is a schematic perspective view of the heater blanket apparatus including a plurality of heater blankets according to the embodiment of this teaching. A part of the structure of FIG. 12 before mounting the plurality of heater blankets is shown. It is sectional drawing of a part of the structure of FIG. FIG. 2 is a cross-sectional view of the structure of FIG. 12 during devalking or other processing. FIG. 6 is a perspective view of power and vacuum routing to the structure of FIG. It is a side view of the heater blanket deployment system of the 1st position by this teaching. It is a side view of the heater blanket deployment system of the 2nd position by this teaching. It is a side view of another heater blanket deployment system by this teaching. It is a side view of another heater blanket deployment system by this teaching. It is a flowchart of the method by this teaching. It is a side view of the aircraft including one or more composite parts formed using the embodiment of this teaching.

It should be noted that some details in the figure have been simplified and illustrated to facilitate understanding of this teaching, rather than to maintain strict structural accuracy, detail, and scale.

From here, an exemplary embodiment of the present teaching, of which examples are illustrated in the accompanying drawings, will be referred to in detail. Where possible, the same reference numbers will be used throughout the drawing to refer to the same or similar parts.

A smart susceptor heater blanket (“heater blanket”) for deautoclave (OOA) curing of composite patches is described, for example, in US Pat. No. 9,174,398. An exemplary patented heater blanket can be used to cure patches on a relatively small rework area.

Embodiments of this teaching may provide methods and equipment for processing large components, such as, for example, OOA debulking of uncured composite parts. Depending on the method and device, it has a size (eg, perimeter, footprint, or external dimensions) that requires prior devalking or other processing in the autoclave due to size or other contributing factors. For example, OOA devaluation of large-scale composite parts such as a plurality of uncured composite plies may be possible. Increasing the blanket size to accommodate large composite parts by pretreatment presents some challenges. For example, a large heater blanket requires long internal wiring with high electrical resistance, and thus requires a high current power source to adequately power the blanket, which is costly. In addition, very large smart susceptor heater blankets are expensive to manufacture and the cost of scrapping irreparable smart susceptor heater blankets is also high. Therefore, the large components have best been both debulked and cured in the autoclave. However, autoclaving is also costly because large amounts of processing gas, such as nitrogen, must be heated, cooled, and reheated during the devalking of large composite parts within the autoclave. It also requires substantial cost of capital and manufacturing flow time for using the autoclave.

Embodiments of the present disclosure may include a processing apparatus that includes a plurality of interconnected heater blankets. This teaching is generally described with reference to the debulking process for brevity, but it will be understood that other treatments such as curing are also conceivable.

The debulking device may include a particular electrical design that requires a relatively low current source and has low electrical interference between adjacent heater blankets. In one embodiment, the debulking device has at least two (ie, two or more) heater blankets in which the number of interconnected heater blankets is determined, for example, by the size of the heater blanket and the size of the composite component being debulked. For example, it may include 8, 12, 16, 20, or more interconnected heater blankets. A modular heater blanket design according to an embodiment of the present teaching can facilitate easy replacement of equipment components and power supply at a lower cost as compared to a single heater blanket design.

It will be appreciated that the actual assembly shown in the figure may include other structures not shown for brevity, and the structures shown may be removed or modified.

FIG. 1 is a heater blanket wire assembly 100 comprising a litz wire 102 and a susceptor wire 104 that can spirally or spirally wrap around the litz wire 102 to form a plurality of susceptor windings around the litz wire. It is a perspective view of a part. As is known in the art, the litz wire 102 is an electrical insulator placed between a plurality of conductive wires 106 electrically isolated from each other and between the susceptor wire 104 and the plurality of conductive wires 106. Includes body 108 and. In one embodiment, the wire assembly 100 is measured from about 0.04 inch to about 0.08 inch, or about 0.06, as measured on the outer surface of the susceptor wire 104, although other dimensions are taken into account. Can have an inch diameter. The wire assembly 100 includes a first end and a second end opposite to the first end, and the wire assembly 100 extends from the first end to the second end. The length of the wire assembly 100 will depend on the size of the heater blanket that forms part of it, but in one embodiment the wire assembly 100 is about 5 to about 100 feet long. obtain.

FIG. 2 is a perspective view of a portion of the outside of a portion of the wire ribbon 200 that includes a plurality of individually spaced wire assemblies 100. The plurality of wire assemblies 100 can be encapsulated or cased together in an electrically extinct and thermally conductive binder 202 such as a silicone binder. In one embodiment, the binder 202 has a thickness of about 0.025 inches to about 0.25 inches, or the heat generated in the susceptor wire by the flow of current through the litz wire to the adjacent workpiece. It may have another thickness suitable for energy transfer. The wire ribbon 200 may include any number of wire assemblies 100, such as at least two, or up to ten or more wire assemblies 100. The wire ribbon 200 is about 0.5 inches to about 12 inches wide, about 2 inches to about 12 inches wide, about 0.5 inches to about 6.0 inches wide, or size constraints, electrical constraints, It may have another suitable width determined by the number of wire assemblies 100 in the wire ribbon 200 and the like.

FIG. 3 is a plan view showing the heater blanket 300 including the wire ribbon 200 of FIG. For illustration purposes, the wire ribbon 200 of FIG. 3 includes four wire assemblies 100A-100D. The heater blanket 300 may include a blanket substrate 302. In one embodiment, the blanket substrate 302 may include one layer of silicone binder to which the wire ribbon is attached using an attachment such as an adhesive. In another embodiment, the blanket substrate 302 may include two layers of silicone binder and the wire ribbon 200 is placed between the two layers. In any case, the wire ribbon is positioned to extend (meander) back and forth across the heater blanket as shown in FIG. The wire ribbon 200 of FIG. 3 is shown with three 180 degree rotations for simplification in consideration of the scale of the figure, while the wire ribbon 200 meanders over the entire heater blanket 300. , For example, 6 to 12 180 degree rotations, or 8 or more 180 degree rotations may be included. Further, the wire ribbon 200 may be formed as a straight ribbon and bent in a desired pattern to form the heater blanket 300, or may extend in another pattern over the entire heater blanket 300. In general, the wire ribbon 200 may cover a suitable percentage of the surface area, perimeter, or footprint of the heater blanket so as to maintain even heating of the debulked articles during the debulking process. ..

The heater blanket 300 further includes a first electrical connector 304 attached to the first end of each wire assembly 100 and a second electrical connector 306 attached to the second end of each wire assembly. In one embodiment, the first electrical connector 304 may be a male connector and the second electrical connector may be a female connector. The paired connectors 304, 306 allow the power supply to be electrically connected to each of the wire assemblies 100A-100D using either series or parallel connections, as described below. Two or more heater blankets 300 may be manufactured.

The two or more heater blankets 300 of FIG. 3 illustrate the dash symbol (300') of the first heater blanket 300 and the second heater blanket 300, which may be the same or have different shapes. , Can be assembled to form the components of the bulking apparatus shown in FIG. However, in general, the length of the wire ribbon 200 within each heater blanket may be similar so that both or all of the heater blankets match the power conditions. In one embodiment, the wire ribbons 200 within each heater blanket 300 may be manufactured such that the lengths of all the wire ribbons vary by less than about ± 10% from the target length. In short, the shortest wire ribbon has a length less than 0.9 times the target length of all wire ribbons for devaluation equipment, and the longest wire ribbon has a length less than 1.1 times the target length. Can have. This ensures that all heater blankets in the debulking device operate with similar heating and cooling characteristics so that uniform and predictable temperatures can be maintained throughout the debulked article. In other embodiments, the wire ribbon 200 within each heater blanket 300 may be manufactured such that the length of all wire ribbons varies by less than ± 20% or less than ± 15%. In other embodiments, the length change may not be a design consideration.

FIG. 5 is a block diagram of a heater blanket device 500 that may be part of a debulking device. In the illustration of FIG. 5, two heater blankets 300, 300'for debulking uncured composite parts according to an embodiment of the present teaching are included, whereas the heater blanket apparatus 500 includes any number of heater blankets. Will be understood to get. FIG. 5 illustrates one or more power supplies 502, 502'including inputs 504 and outputs 506. As described below, one power source 502 may power all heater blankets 300, 300'and separate power sources 502, 502' may power each heater blanket 300, 300'. FIG. 5 further illustrates a junction box 508 having an input (eg, output 506 of power supply 502). The junction box provides a first input / output 510 to each of the first connectors 304 and a second input / output to each of the second connectors 306. The input 510 / output 512 from the junction box 508 will depend on the particular design or configuration of the heater blanket device 500, as described below. The heater blankets 300, 300'are electrically connected to the input 510 / output 512 of the junction box 508 via the illustrated electrical connectors 304, 306 and receive power via the input 510 / output 512.

FIG. 5 further illustrates a plurality of thermal sensors 514, such as thermocouples. The thermal sensor 514 is in thermal communication with one or more of the heater blankets 300, 300'. 516. In one embodiment, the plurality of thermal sensors are in thermal proximity to each of the heater blankets 300, 300'. It monitors the temperature of the heater blankets 300, 300'and helps maintain a uniform heater blanket temperature range during debulking. The thermal sensor 514 may transfer temperature data to the controller 518, for example via a wired or wireless connection or interface 520. The controller 518 electrically communicates with the power source via, for example, the communication cable 522 to control the power source.

The master controller 518 is electrically connected to a plurality of slave controllers 524 and 524'and can control those slave controllers 524 and 524'. Each slave controller 524, 524'is electrically connected to one of the heater blankets 300, 300', respectively. Each slave controller 524, 524'monitors and controls one of the heater blankets 300, 300'. Further, each slave controller 524, 524'can receive data and instructions from the master controller 518 and pass operation data for the heater blankets 300, 300' to the master controller 518. The master controller 518 can control the output 506 from the power supplies 502, 502'based on the heater blanket operation data.

During use, each litz wire 102 of each wire ribbon 200 is electrically connected to a power source 502. The current from the power source 502 flowing through the litz wire 102 creates a magnetic field in each susceptor wire 104 of each wire ribbon 200 of each heater blanket 300. The magnetic field then generates heat in the wire ribbon 200 that heats each heater blanket 300. The susceptor wire contains, at least in part, the Curie temperature (T _c ) resulting from a particular component of the susceptor wire. Induction heating of the susceptor wire can be reduced when the susceptor sleeve becomes non-magnetic as soon as it reaches the Curie temperature. Reduced heating of the susceptor sleeve can result in reduced conduction heating of the structure. At low temperatures, the magnetic permeability of the susceptor wire 104 is high, thus the skin thickness of the susceptor wire 104 is small, and the magnetic field induces a strong eddy current with a relatively high heat output that heats the heater blanket 300. As the temperature of the susceptor wire 104 increases, the magnetic permeability of the susceptor wire 104 decreases to a low value, and the skin thickness of the susceptor wire 104 increases. At high temperatures, the skin thickness is greater than the radius of the susceptor wire 104, and the eddy currents in the susceptor wire 104 interfere with each other, thereby weakening the eddy current. A weak eddy current has a relatively low heat output, so that the heater blanket 300 produces less heat. As a result, each part of the susceptor wire 104 becomes its own temperature controller and maintains a uniform temperature without changing the current applied to the litz wire 102. Temperature self-regulation occurs locally and continuously along the length of each wire ribbon 200, thus maintaining the desired temperature within the temperature range everywhere along the length of the wire ribbon 200. It is maintained throughout the area of the heater blanket 300. Unless otherwise stated, the terms "smart susceptor heater blanket,""susceptor heater blanket," and "heater blanket" as used herein refer to heater blankets that are temperature self-regulating.

As shown in FIG. 4, at least two heater blankets 300, 300'are placed adjacent to each other during the debulking operation, for example to increase the area that can be debulked at the same time. The two or more heater blankets 300, 300'can be electrically connected to the power source 502 either in series or in parallel, as described below.

Arrows located near the connectors 304, 306 in each wire assembly 100 of FIG. 4 provide current polarity to each wire assembly 100, more specifically, via each litz wire 102 of each wire assembly 100. Represents the direction of AC current flow at a given point in doing so. Current is applied to each litz wire 102 so that it flows through all adjacent litz wires 102 in the direction opposite to the direction of current flow. In short, during use, the current in each wire segment is 180 degrees out of phase with each adjacent wire segment. As shown in FIG. 4, the current flows from the first connector 304 to the second connector 306 for the wire assemblies 100A and 100C and towards the first connector 304 for the wire assemblies 100B and 100D. Flows from the second connector 306. In short, the current flows in the first direction for the wire assemblies 100A and 100C (generally indicated by a relatively long dashed line) and their respective adjacent wire assemblies 100B and 100D (generally indicated by a relatively short dashed line). ) Flows in the second direction, and the second direction is opposite to the first direction.

In addition, as shown in FIG. 4, for explanatory purposes, each wire ribbon 200, 200'has a plurality of parallel major segments positioned adjacent to at least one other major segment 400, 400'. Alternatively, it may include legs 400, 400'. As shown, the rightmost major segment 400 for the heater blanket 300 is positioned adjacent and parallel to the leftmost major segment 400'for the heater blanket 300', so that the wire assembly 100A is the wire assembly 100A. Positioned adjacent to'. As shown, the current flow through the wire assembly 100A of the rightmost major segment 400 is opposite to the current flow through the wire assembly 100A'of the leftmost major segment 400'. However, it will be understood that this happens especially when both blankets are connected to the same power supply. In general, two or more power supplies will operate at slightly different frequencies, so, for example, the current in the rightmost major segment 400 will be in opposite directions in only about half the time. This will lead to at least a small increase in the magnetic field.

The opposite current flow for all adjacent wire assemblies 100A-100D, 100A'-100D' is the opposite field where any magnetic field not absorbed by the susceptor winding is generated by the two adjacent major segments 400. Guarantee that it is minimized by the cancellation of. This particular design element of the individual smart susceptor heater blanket 300 will, at least in part, affect the heating of the heater blanket 300, generally the debulking device, and any item being heated by it. Allows two or more heater blankets 300 to be placed directly adjacent to each other without causing or resulting in interference or thermal interference.

Various connection configurations are conceivable for electrically connecting each heater blanket to the power supply and / or junction box. In one embodiment shown in FIG. 6, a pair of connector types can be used at each end of the wire ribbon 200. In this embodiment, litz wires with the same polarity (eg, the same current direction) are classified into the same connector, allowing proper electrical connection to adjacent blankets or electrical connection to a power source. In FIG. 6, the connector 600 is a female connector having a negative property (that is, a flow of current toward the connector) connected to the first ends of the wire assemblies 100B and 100D, and the connector 602 is the wire assembly 100B. And a male connector with positive properties (ie, the flow of current away from the connector) connected to the second end of the 100D, the connector 604 is connected to the first end of the wire assemblies 100A and 100C. It is a female connector having a negative electrode property, and the connector 606 is a male connector having a positive electrode property connected to the wire assemblies 100A and 100C.

FIG. 7 shows the heater blanket 300 (eg, the first heater blanket) of FIG. 6 when it can be electrically connected to the second heater blanket 300'using a series electrical connection. The connectors 600, 606 of the first heater blanket 300 and the connectors 602', 604'of the second heater blanket 300', for example, with the power supply 502 and / or the junction box 508 via an electrical connector as shown. It is electrically connected or connected. The connectors 602, 604 of the first heater blanket 300 are electrically connected to the connectors 600', 606' of the second heater blanket 300', as shown.

FIG. 8 shows a first heater blanket 300 when it can be electrically connected to a second heater blanket 300'using parallel electrical connections. The electrical connectors 600-606, 600'-606' are electrically connected or connected to the power supply 502 and / or the junction box 508, for example, via an electrical connector as shown. In one embodiment, each power source 502 in FIG. 8 is the same power source 502. In another embodiment, each power source 502 in FIG. 8 is a different power source 502, for example, reducing the current requirement for each power source.

FIG. 9 is a plan view of the debulking assembly including the plurality of heater blankets 300A-300P in use and the uncured composite part of the article 900 to be debulked, and FIG. 10 is a cross-sectional view thereof. In this embodiment, 16 heater blankets (eg, corresponding to 16 heating zones) 300A-300P are mounted adjacent to each other, eg, as described above or using different coupling designs, and power supplies. Is electrically connected to. In one embodiment, each heater blanket 300A-300P can be attached to a different power source, as described above, for example to reduce current requirements. FIG. 10 shows the heater blanket 300A-300P covering the composite component 900, but the composite component 900 can be placed over the heater blanket 300A-300P. It will also be found that the heater blanket can be placed both above and below the composite part 900 during devalking. Further, the composite component 900 of FIG. 10 shows four laminates 900A-900D such as a prepreg, wherein the composite component 900 is an arbitrary number of laminates laminated together, for example, 40 or more layers. It will be understood that it can include layers of. Further, the composite component 900 may include a three-dimensional (3D) woven prepreg rather than a laminate.

In FIG. 9, the plurality of heater blankets 300A-300P include a personalized shape designed to match the shape of the debulked composite part 900. Each heater blanket of the plurality of heater blankets 300A-300P may have the same or different perimeter and shape as all other heater blankets 300A-300P. Some heater blankets of multiple heater blankets 300A-300P may have the same perimeter and shape as other heater blankets 300A-300P, while other heater blankets may be with other heater blankets 300A-300P. It has different perimeter shapes and lengths. In one embodiment, each heater blanket 300A-300P may have a wire ribbon 200 as described above. In embodiments that include only a single power source that powers all heater blankets 300A-300P, each wire ribbon for each heater blanket 300A-300P is less than ± 20%, less than ± 15%, or less than ± 15% of the common target value. It can be designed to have a length that varies by less than ± 10%, so the power requirements per heater blanket 300A-300P are consistent or similar to all other heater blankets 300A-300P. The plurality of heater blankets 300A-300P are mechanically attached to the mounting surface or support 1000 using, for example, a plurality of fasteners 1002 (shown only in the heater blanket 300E of FIG. 10 for simplification). Can be done. Fastener 1002 may maintain each blanket in a fixed position with respect to one or more adjacent blankets. The composite part 900 may rest on the bottom or work surface 1004 of a contoured layup mandrel or the like during devalking. In embodiments where each heater blanket 300A-300P is powered by a separate power source, the outputs of all power sources may be the same, or the outputs may match the requirements of the heater blanket to be powered. Good.

In one embodiment, the composite part 900 may be placed in a vacuum bag 1006 attached to the vacuum source 1008 during devalking. During the devalking operation, power is applied to each of the heater blankets 300A-300P, while vacuum is applied to the vacuum bag 1006 by the vacuum source 1008. The heater blanket 300A-300P can be designed to reach and maintain the target temperature, thus satisfying the requirements for debulking the composite part 900 and heating the composite part 900 to a desired temperature. The effect of the smart susceptor provides local temperature control to eliminate variations in heat load (to account for variations in thermal load).

In one embodiment, each of the 16 heater blankets can be controlled through the use of 16 slave controllers 524 (FIG. 5), each controlling and monitoring one of the heater blankets 300A-300P. In one embodiment, the master controller 518 (FIG. 5) tilts the temperature of each heater blanket 300A-300P, either directly or through the slave controller 524, until each heater blanket 300A-300P reaches a temperature target or set point. Can be defined. The 16 slave controllers use, for example, a thermal sensor 514 to power the 16 heater blankets via a feedback control loop based on the measured temperature values in each zone. The software in controller 518 may include software algorithms that investigate multiple temperatures for each zone. The maximum temperature of multiple measurement points can eventually be used for control at all points. The maximum temperature during a temperature gradient can vary from location to location within the zone over a period of temperature gradient and / or temperature quiescentity.

Each of the one or more power sources may include a load adjusting operation that can be used to monitor the health of each smart susceptor heater blanket 300A-300P. The master controller 518 and / or the slave controller 524 may monitor the health of each heater blanket 300A-300P both before and during devalking operation. Controller 518 may further monitor the operation of the vacuum source 1008 and the vacuum in the vacuum bag 1006. Process data may be continuously captured and recorded in the data file before, during and after the bulking operation of real-time or subsequent analysis.

Multiple heater blankets 300A-300P can be assembled in an enclosure or placed between two or more hard and / or flexible layers, thus multiple modular heater blankets 300A-300P are sub-heater blanket assemblies. It will be understood that it will be an assembly.

Various embodiments for processing composite parts are conceivable. For example, FIG. 11 is a cross-sectional view of the heater blanket device 110 during the OOA process for debulking a plurality of layers 1102, but other processes such as the curing process use heat application from the heater blanket device 110. It will be understood that it can be done. FIG. 11 shows four layers 1102, such as four prepreg layers to be debulked, but any number of layers 1102, such as 40 or more layers, may be debulked. Layer 1102 may be laminated on a layup mandrel 1104 such as an invar backing plate.

In addition to the layers 1102 and layup mandrel 1104 to be debulked, FIG. 11 shows the protective release layer 1106, two or more heater blankets 1108, one or more breather layers 1110, 1112, and the layup mandrel 1104 with double-sided adhesive tape 1116. The sealed vacuum bag 1114 is illustrated. The protective release layer 1106 can be, for example, ethyl fluorinated propylene (FEP), ethylene tetrafluoroethylene (ETFE), or another suitable material. The vacuum bag 1114 may have an opening to receive the vacuum port 1118.

During devalking, layer 1102 is evacuated by evacuating air, nitrogen, or another gas through vacuum port 1118 using vacuum source 1008 (FIG. 10). During debulking, an electric current is applied to each of the heater blankets 1108 to heat the heater blanket 1108 and then layer 1102 during the debulking process. In one process, the heater blanket can tilt to a target temperature of 160 ° F ± 10 ° F while the processing parameters fluctuate. During the temperature gradient, the temperature of the heater blanket 1108 is monitored using, for example, a thermal sensor 514 (FIG. 5). If the thermal sensor detects, for example, a temperature of 110 degrees Fahrenheit during the temperature gradient, the master controller 518 may start a process timer while the temperature rises to a target of 160 degrees Fahrenheit and during further processing. .. Once the process timer reaches the desired value, for example 3 hours, current can be removed from the heater blanket 1108 and the heater blanket device 1100 can be cooled. Recording of process data can continue until a particular temperature is reached, for example 110 degrees Fahrenheit. Once the process termination temperature is measured by the thermal sensor 514, the interior of the heater blanket device 1100 is ventilated, the vacuum bag 1114 is removed and the debulked layer 1102 can be moved to an autoclave or oven for final curing. ..

In this embodiment, two or more heater blankets 1108 are located in the vacuum bag 1114 during the debulk of layer 1102. Therefore, devalking of layer 1102 can be performed outside the autoclave or oven. Thus, the present embodiment provides a one-sided heat source (heater blanket 1108) that provides local heating directly to a large surface laminate (layer 1102) for debulking. Direct application of local heating can result in laminate debulk corresponding to the results obtained by conventional debulk methods, including various benefits. For example, the process described above does not require heating the entire space of the oven or autoclave, which reduces processing time and energy costs. Heating is provided by alternating current (AC) and / or direct current (DC) power sources, thus eliminating the need for natural gas, which simplifies equipment requirements. In addition, because the heating is local, the cooling of the assembly can be relatively rapid without the need for active cooling. In addition, the entire tool and support structure is used to form the laminate into the desired shape, reducing spatial requirements compared to autoclaves or ovens. As explained earlier, smart susceptor heater blankets are self-regulating with respect to temperature. The wire assembly 100 continues to heat, whereby the smart susceptor heater blanket and layer 1102 are heated until _{the susceptor wire 104 locally reaches its Curie temperature (T c).} Once reached T _C, localized heating is cooled susceptor wire 104 to below T _c, heated until the restart is stopped. Therefore, the heater blanket and the layer 1102 heated by the heater blanket obtain the desired temperature without overheating.

FIG. 12 is a schematic perspective view of another embodiment of the heater blanket apparatus 1200 that can be used, for example, to debulk a plurality of uncured plies in a composite laminate. In FIG. 12, the plurality of heater blankets are mounted on a frame or fixture to provide a heater blanket device for heating the plurality of layers during a process such as a debulking operation. The illustration in FIG. 12 includes a first subsection 1202 with a layup mandrel 1204 and a second subsection 1210 with 16 separate heater blankets 1212, but with two or more heater blankets 1212. A heater blanket device is conceivable. Each heater blanket 1212 is electrically connected to a power source, for example, at a first connector 304 through one or more cables 1214 connected to the wire ribbon 200. The plurality of heater blankets 1212 may be connected to the power supply either in parallel (as shown in FIG. 12) or in series. Series and parallel connections are described above. During devalking, the second subsection 1210 can be lowered onto the first subsection 1202, and a layer of laminated board to be debulked is between the first subsection 1202 and the second subsection 1210. More specifically, it is placed between the layup mandrel 1204 and the heater blanket 1212. The plurality of heater blankets 1212 may be supported by the frame 216.

FIG. 13 shows a second subsection 1210 prior to installation of the heater blanket 1212, and further shows a vacuum bag 1300 when a plurality of heater blankets 1212 are placed between the vacuum bag 1300 and the layer to be debulked during debulking. .. The vacuum bag 1300 allows partial formation around the layer in which the vacuum is debulked.

FIG. 14 is a cross-sectional view illustrating a portion of the first subsection 1202 and the second subsection 1210, including a plurality of uncured composite plies 1400 prior to devalking. FIG. 14 shows a vacuum port 1402 penetrating the vacuum bag 1300. When fluid communicating with the vacuum source 1008 (FIG. 10), the vacuum port 1402 allows the composite ply 1400 to be evacuated during devalking by aerating air, nitrogen, vapor, or another gas. FIG. 14 further illustrates one of a plurality of cables 1214 electrically connected to one of the heater blankets 1212 using the first connector 600 and the second connector 1404. The reinforced seal 1406 may be attached to the top surface of the vacuum bag 1300 to prevent tearing around the opening through which the wire ribbon 200 penetrates and to form a seal to prevent a decrease in vacuum during bulking.

The second subsection 1210 may include other properties required to hold the vacuum during processing. For example, FIG. 14 shows an elongated T7 (registration) that physically contacts the layup mandrel 1204 during processing and maintains a seal with the layup mandrel 1204, typically containing silicone or another sufficient material. An elongated seal 1408, such as a seal or another reusable elongated seal, and a spacer 1410 that spaced the vacuum bag 1300 and the layup mandrel 1204 to maintain vacuum are illustrated.

FIG. 14 further illustrates one of a plurality of straps 1412 that attaches a second subsection 1210 to a portion of the frame 1216, eg, to a type I beam described below. The plurality of straps 1412 may be manufactured from a material such as fiberglass reinforced silicon. The plurality of straps 1412 can be attached to the second subsection 1210, more specifically the vacuum bag 1300, using silicone adhesive. For example, a toughened layer 1414, such as fiberglass reinforced silicon, may be placed between the plurality of straps 1412 and the vacuum bag 1300 to reduce or prevent damage to the vacuum bag 1300 in use.

The heater blanket device 1200 of FIG. 14 may include other structures such as an edge breather 1416 that is in physical contact with the vacuum port 1402 and is spaced between the vacuum port 1402 and the layup mandrel 1204. The edge breather 1416 may be a porous layer that allows air and / or other gases to be exhausted from the composite ply 1400 through vacuum port 1402 during debulking of the composite ply 1400. The edge breather 1416 can be, for example, one or more layers of Airweave® N-10. FIG. 14 further illustrates the aforementioned protective release layer 1106, such as FEP, and the edge dam 1418, which can be used for alignment and positioning of the plurality of composite plies 1400.

FIG. 14 shows the details of the structure of FIG. FIG. 15 further illustrates fasteners 1002 that can be used to physically and mechanically connect a plurality of heater blankets 1212 to a vacuum bag 1300 and a mounting surface or support 1500. As illustrated, the blanket device 1200 has an additional elongated seal 1408 that physically contacts the layup mandrel 1204 during processing and maintains a seal with the layup mandrel 1204, and a vacuum to maintain vacuum. It may further include a spacer 1410 that spacing the bag 1300 and the layup mandrel 1204.

FIG. 16 illustrates a support beam 1600, such as a type I beam or other rigid beam, which may be part of frame 1216 (FIG. 12). The support beam 1600 can be used as a mounting point for routing power, vacuum, etc. for connection to the second subsection 1210. FIG. 16 illustrates a vacuum hose 1602 connected to a type I beam at the first end and to a vacuum port 1402 at the second end. The vacuum hose 1602 may include a vacuum port 1402 and a fitting 1604 suitable for connection to the vacuum supply section 1008 (FIG. 10). For example, a power cable 1606 electrically connected to one or more power sources 502 via junction box 508 is a type I beam for electrical connection with cable 1214 connected to wire ribbon 200 of heater blanket 1212. Can be routed along. The power cable 1606 may include an electrical connector 1608 that facilitates electrical connection with the cable 1214. Each of the plurality of straps 1412 can be physically connected to the support beam 1600 using the bracket 1610. Strap 1412 is used to support the vacuum bag 1300 and other structures of the second subsection 1210 when in the stationary / storage position.

During the debulking process or other heating process, with reference to FIG. 14, multiple layers 1400 to be debulked can be placed on the layup mandrel 1204. The second subsection 1210 is then lowered onto the first subsection 1202, thus allowing the plurality of heater blankets 1212 to physically approach and thermally communicate with the plurality of layers 1400. As shown, the protective release layer 1106 may be placed between the plurality of heater blankets 1212 and the plurality of layers 1400. It will be appreciated that the structure of FIG. 14 may include other properties, structures or layers not illustrated for brevity, while the illustrated elements may be removed or modified.

For example, various embodiments for implementing the heater blanket structure described above in a production environment are conceivable. While the following description describes the structure and method in terms of production flow, it will be understood that it may be used in non-production environments. Structural elements such as support frames and lift assists can be utilized to provide an efficient production flow with sufficient production of the product.

FIG. 17 illustrates a heater blanket deployment system 1700 according to an embodiment of the present teaching. Deployment system 1700 of FIG. 17 includes a first workstation 1702A and a second workstation 1702B that may be similar to the first workstation 1702A. Since workstations 1702A and 1702B may contain similar structures, for the sake of brevity, in FIG. 17, the first workstation 1702A is an identifier ending with an "A" classification element, while the second For workstation 1702B, identifiers ending with the "B" classification element are referred to.

Each workstation 1702 may include a heater blanket device 1704, each of which may be similar or different from the heater blanket device 1200 of FIG. Thus, each workstation 1702 may include the aforementioned smart susceptor heater blanket 1212 and vacuum bag 1114, each of which may be mounted or mounted on a mounting surface or support 1706. The two support surfaces 1706A, 1706B can be physically coupled together using one or more struts or beams 1708 to keep the support surfaces 1706 in a fixed position with respect to each other. One or more struts 1708 may be mechanically coupled to each of the support surfaces 1706A, 1706B using any suitable fasteners such as bolts, welds, pins and the like.

Each workstation 1702 may further include a working surface 1710 such as a layup mandrel that can be contoured to a material to be treated such as a plurality of uncured composite plies to be debulked or a workpiece 1712. Each work surface 1710 may be positioned by a support 1714 such as a table.

Deployment system 1700 may further include a base 1716 in which utilities such as power and vacuum are routed or located within it. The base 1716 can be positioned or placed between the first workstation 1702A and the second workstation 1702B as shown in FIG. The base 1716 may include rods or bars 1718 to which the support surfaces 1706A, 1706B can be rotatably attached. In one embodiment, the rod 1718 may remain fixed and the support surface 1706 may rotate around the rod 1718. In another embodiment, the support surface 1706 can be fixedly mounted to the rod 1718, whereas the rod 1718 rotates inside the base 1716. Therefore, the first support surface 1706A, the second support surface 1706B, and the base 1716 substantially form a Y-shaped frame placed between the first work surface 1710A and the second work surface 1710B. Can be. In this configuration, the workpiece in one of the workstations is debulked or otherwise treated only when the workpiece in the other workstation has not been debulked or otherwise treated.

During use, the first material 1712A to be processed is positioned on the first working surface 1710A and the first support surface 1706A is above the first material 1712A to be processed as shown in FIG. Can be rotated. Power supplied from one or more power sources 502 (FIG. 5) in the base 1716 or routed to the base 1716 from a remote power source can be applied to the first heater blanket 1212A, whereby the first heater. The blanket 1212A is heated. The vacuum provided to the vacuum supply device 1008 (FIG. 10) in the base 1716 or routed to the base from the remote vacuum supply device 1008 can be applied to the first vacuum bag 1114A, thereby, for example, as described above. Air and / or other gases are removed between the layers of the first material 1712A to be treated.

During the treatment of the first material 1712A, the second material 1712B to be treated may be positioned on the second working surface 1710B in preparation for the treatment. Thus, while one material is being treated on one working surface 1710, the other material may be prepared for processing on the other working surface 1710.

After the first material 1712A has been processed on the first working surface 1710A and the second material 1712B has been prepared on the second working surface 1710B, the deployment system 1700 has been rotated and viewed from the first position in FIG. It may be repositioned in the second position of 18. The treated first material 1712A can be removed from the first working surface 1710A and replaced with an untreated material during the treatment of the second material 1712B. After being removed from the first working surface 1710A, the treated first material 1712A can be used, transported, further treated, etc., for example.

FIG. 17 illustrates an angle θ of about 90 degrees formed by the first support surface 1706A of the first workstation 1702A and the second support surface 1706B of the second workstation 1702B, for example. It will be understood that other angles such as, from about 90 degrees to about 135 degrees are possible.

Therefore, in the deployment system of FIGS. 17 and 18, two workstations 1702 are provided using a relatively dense work area. With a base 1716 located between the two workstations, equipment that supplies utilities such as power and vacuum is located near both workstations 1702 and can provide utilities to both workstations 1702. Further, one workstation 1702 can be used to process one workpiece 1712, while the other workstation 1702 is to position and prepare another workpiece 1712 for processing. used. Utility requirements are about half that of a deployment system that processes two workpieces at the same time, as utilities such as power and vacuum can be supplied to only one workstation at a time.

FIG. 19 illustrates another embodiment of a heater blanket deployment system 1900 that includes a first workstation 1902A and a second workstation 1902B. It will be understood that additional workstations that match the workstation 1902 shown are conceivable. Deployment system 1900 of FIG. 19 includes a base 1904 with a vertical tower 1906. The first workstation 1902A included a first mounting surface or support surface 1908A movably attached to the vertical tower 1906, and the second workstation 1902B was movably attached to the vertical tower 1906. Includes a second mounting surface or support surface 1908B. Various mechanical systems, electrical systems, electromechanical systems, manual systems and automatic systems for raising and lowering the mounting surface 1908 with respect to the working surface 1710 can be considered.

Utilities such as power and vacuum can be routed to the heater blanket 1212 and vacuum bag 1114 of each workstation via the base 1904 and the vertical tower 1906. In another embodiment, one or more power sources 502 (FIG. 5) and / or vacuum supply device 1008 (FIG. 10) may be located inside the base 1904.

Movable mounting of the support surface 1908 to the vertical tower 1906 allows each support surface 1908 for each workstation 1902 to be separately lowered towards the work surface 1710 and work piece 1710, or the work surface 1710 and work piece. It can be raised away from the object 1710. In this embodiment, processing of the workpiece 1712 can occur simultaneously on multiple workstations 1902. Simultaneous processing can require at least one or more power sources and evacuation devices that are expected to produce higher than the deployment system 1700 of FIG. 17, as power and evacuation can be at least about twice as high. However, the utility between the two workstations 1902 and the utility in close proximity to the two workstations 1902 allows the two workstations 1902 to use the same power and vacuum supply. This may provide a deployment system 1900 with reduced component counts and equipment costs compared to, for example, two separate workstations with different power and vacuum supply devices. Further, the deployment system 1900, which enables simultaneous processing of the workpiece 1712, can provide a manufacturing flow in which the production yield is increased as compared with the deployment system, which enables serial processing instead of parallel processing of the workpiece. In addition, the structure of FIG. 19 is a raised support structure with a flexible deployment system that does not require rotational access to the material being processed and thus has the potential to reduce complexity and cost. The heater blanket 1212 and the vacuum bag 1114 move vertically toward and away from the material being processed and do not move horizontally across the entire material being processed. However, similar to the design of FIGS. 17 and 18, the floor surface under the base 1904 of the deployment system 1900 of FIG. 19 may optionally include a reinforced concrete underground utility routed to the base 1904. Let's go. As mentioned above, the designs of FIGS. 17-19 include rigid support surfaces to which the heater blanket 1212 and vacuum bag 1114 are attached during use.

FIG. 20 shows a heater blanket deployment system 2002 that includes the use of an overhead system 2002 for suspending a first heater blanket assembly 2004A on a first workstation 2006A and a second heater blanket assembly 2004B on a second workstation 2006B. Another embodiment is illustrated. The overhead system 2002 allows each heater blanket assembly 2004 to be lowered towards the work surface 1710 and raised away from the work surface 1710 in a vertical direction perpendicular to the horizontal work surface 1710. The heater blanket deployment system 2000 of FIG. 20 is via a plurality of vertical supports 2008, an overhead framework 2010 supported by the vertical supports 2008, and power and vacuum conduit 2014 supplied via the power cable 2012. A utility such as a vacuum supplied through the device can include an optical base 2011 that can be supplied to the heater blanket assembly 2004 through it.

Deployment system 2000 is a plurality of winch assemblies 2016, each configured to raise and lower the heater blanket assembly 2004 separately by winding and unwinding a lifting strap 2018 physically attached to the heater blanket assembly 2004. Can be further included.

Deployment system 2000 may provide a rigid framework that includes a flexible lifting strap 2018 and a vertical support 2008 as a support structure for the heater blanket assembly 2004 and an overhead framework 2010. Although FIG. 20 illustrates the optical base 2011, utilities such as power 2012 and vacuum 2014 can be routed from different locations throughout the overhead framework 2010. The base 2011 is optional as it does not need to support any lifting mechanism of the heater blanket assembly 2004. Therefore, significantly strengthened concrete supporting the base 2011 and the heater blanket lifting mechanism may not be required. If the base 2011 is omitted, it is no longer necessary to route underground for utilities such as power and vacuum to the base 2011, which reduces construction costs and installation time. The overhead framework 2010 is also used to support a power cable routed to one or more system power requesters in base 2011 and then routed to the heater blanket assembly 2004 via power cable 2012. obtain.

Further, the deployment system 2000 is substantially in both the storage position illustrated by the first workstation 2006A and the debulk position illustrated by the second workstation 2006B, and in each intermediate position. Holds the flexible heater blanket assembly 2004 in a horizontal position. Raised mounting surfaces 1706, 1908 are required by holding the heater blanket assembly in a substantially horizontal position. This allows for a flexible heater blanket assembly 2004 that is more easily matched to the different and more extreme contours of the workpiece 1712. Further, when the heater blanket assembly 2004 is lowered onto the workpiece 1712, the heater blanket assembly 2004 physically contacts the center of the workpiece 1712 and forms a drape above the workpiece from the center to the outside. To do. This can reduce or prevent the protective release layer 1106 from moving or shifting during deployment. Since the workpiece 1712 is sticky when the heater blanket assembly 2004 is lowered onto the workpiece 1712, any lateral movement of the heater blanket assembly 2004 after contact with the workpiece 1712 is adversely affected. , The position of the workpiece 1712 may be shifted. By lowering the heater blanket assembly 2004 onto the workpiece 1712 perpendicular to the initial center contact with the workpiece 1712, lateral movement between the workpiece 1712 and the heater blanket assembly 2004 and their misalignment are reduced. Or it can be prevented.

In some embodiments, the structures described herein as vacuum bags are disposable vacuum bags or disposable vacuum bags that provide a vacuum chamber into which the workpiece is inserted and then sealed internally during the debulking process. It will be understood that it can be a vacuum bag, such as a disposable vacuum bag (see, eg, vacuum bag 1006 in FIG. 10). In another embodiment, the vacuum bag is a single sheet of flexible material that forms a enclosed and sealed vacuum chamber used to provide vacuum around the workpiece with another structure such as a layup mandrel. Alternatively, it may be a vacuum film such as two or more laminated sheets.

FIG. 21 is a flowchart illustrating a method for processing the first workpiece and the second workpiece 2100 in the deployment system according to the embodiment of the present teaching. At 2102, the first workpiece may be placed on the first working surface of the first workstation. The first heater blanket assembly, including the first smart susceptor heater blanket and the second smart susceptor heater blanket, is first from a first position away from the first workpiece, as shown by 2104. Can move to a second position close to the work piece. Next, in 2016, the first smart susceptor heater blanket and the second smart susceptor heater blanket may be powered to heat the first workpiece. At 2018, the first vacuum bag may be evacuated to remove gases such as air and nitrogen from the first workpiece.

In 2010, the second workpiece may be placed on the second working surface of the second workstation. The second heater blanket assembly, including the third smart susceptor heater blanket and the fourth smart susceptor heater blanket, is from a third position away from the second workpiece, as shown by 2112. Can move to a fourth position close to the work piece. Next, at 2114, the third smart susceptor heater blanket and the fourth smart susceptor heater blanket may be powered to heat the second workpiece. At 2116, the second vacuum bag may be evacuated to remove gases such as air and nitrogen from the first workpiece.

It is understood that in this specification, eg, FIG. 21, one or more of the illustrated actions may be performed in a different order than the one or more separate actions and / or stages and / or illustrated. Will be done.

The devices described herein can be used for debulking or other processing operations on composite parts. For example, FIG. 22 illustrates an aircraft 2200 containing composite parts that can be debulked or processed using the embodiments of this teaching. In one particular use, horizontal stabilizer 2202, vertical stabilizer 2204, and / or other aircraft structures can be processed as described above.

Therefore, the design of the individual smart susceptor heater blankets allows the heater blankets to be placed directly adjacent to each other without causing electromagnetic or thermal interference between the heater blankets. Within each wire ribbon and within the outermost conductors of the adjacent wire ribbons, the currents of any two adjacent conductors will generally always travel in opposite directions. This ensures that any magnetic field not absorbed by the susceptor winding is minimized by the release of the opposite fields generated by the two adjacent wires. Other embodiments are conceivable, for example, where the conductor at the blanket edge is powered by another power source. In general, heater blankets are relatively large and contain many conductors, so any interference between the outermost conductors of adjacent blankets will be manageably small.

With the use of several interconnected heater blankets, a single large heater blanket can be used to further debulk or otherwise process larger workpieces than previously used in the field outside the autoclave. become able to. If a large heater blanket is damaged, the entire heater blanket will need to be replaced. If one of the heater blankets in the assembly described herein is damaged, the modular design with multiple heater blankets will replace only one of the subunits. In addition, the high currents and voltages required to drive multiple litz wires within a single large blanket are costly and dangerous to manufacturing personnel. By using multiple power sources to power multiple heater blankets, the current and voltage used can be reduced, increasing safety for manufacturing personnel.

Further, the present disclosure includes embodiments according to the following provisions.
Clause 1. A heater blanket deployment system: a first workstation comprising a first smart susceptor heater blanket and a second smart susceptor heater blanket located adjacent to the first smart susceptor heater blanket. During the processing of the first heater blanket assembly and the first workpiece, the first smart susceptor heater blanket and the second smart susceptor heater blanket are configured to cover the first working surface. A first workstation with a first working surface; a second workstation located adjacent to a third smart susceptor heater blanket and a third smart susceptor heater blanket. During the processing of the second heater blanket assembly with the fourth smart susceptor heater blanket and the second workpiece, the third smart susceptor heater blanket and the fourth smart susceptor heater blanket provide the second work surface. With a second workstation having a second working surface configured to cover; with a frame supporting a first heater blanket assembly and a second heater blanket assembly; from a frame, a first A heater blanket deployment system with at least one power source configured to power a workstation and a second workstation.
Clause 2. The frame is configured so that the first heater blanket assembly can be moved towards and away from the first work surface, and the second heater blanket assembly is the second work surface. The heater blanket deployment system according to Clause 1, which is configured to be able to move towards and away from the second working surface.
Clause 3. The heater blanket deployment system according to Clause 2, wherein the frame further comprises a first mounting surface coupled to a first heater blanket assembly and a second mounting surface coupled to a second heater blanket assembly.
Clause 4. The first workpiece is configured so that it can be processed in the first workstation only when the second workpiece in the second workstation is not processed, as described in Clause 3. Heater blanket deployment system.
Clause 5. Clause 3 further comprising a base mechanically connected to the first mounting surface and the second mounting surface, the first mounting surface, the second mounting surface and the base forming a Y-shaped frame. Heater blanket deployment system as described in.
Clause 6. The frame is configured to lower the first heater blanket assembly towards the first working surface and raise the first heater blanket assembly away from the first working surface, and further An overhead frame with multiple winches configured to lower the second heater blanket assembly towards the work surface and raise the second heater blanket assembly away from the second work surface. The heater blanket deployment system according to 1.
Clause 7. It further comprises a plurality of lifting straps attached to one of the first heater blanket assembly and one of the second heater blanket assemblies, with the plurality of winches using the plurality of lifting straps towards the first work surface. The first heater blanket assembly is configured to be lowered and away from the first working surface, and a plurality of lifting straps are used to raise the second working surface. The heater blanket deployment system according to Clause 6, which is configured to lower the second heater blanket assembly towards and raise the second heater blanket assembly away from the second working surface.
Clause 8. The first workstation further comprises a first vacuum bag; the first workstation is configured such that the first vacuum bag covers the first working surface during the processing of the first workpiece. The second workstation further comprises a second vacuum bag; the second workstation so that the second vacuum bag covers the second working surface during the processing of the second workpiece. The frame is further provided with a base placed directly between the first and second workstations; the heater blanket deployment system is a first vacuum bag and a second vacuum bag. The heater blanket deployment system according to Clause 1, further comprising a vacuum supply device that communicates with and fluidly; at least one power supply and vacuum supply device is located within the base of the frame.
Clause 9. At least a first elongated seal configured to maintain a first vacuum between the first heater blanket assembly and the first working surface, and a second heater blanket assembly and the second working surface. The heater blanket deployment system according to Clause 8, further comprising at least a second elongated seal configured to maintain a second vacuum in between.
Clause 10. A first protective release layer covering the first smart susceptor heater blanket and the second smart susceptor heater blanket, and a second protective release layer covering the third smart susceptor heater blanket and the fourth smart susceptor heater blanket. Further provided, the heater blanket deployment system described in Clause 1.
Clause 11. The first protective release layer is positioned between the first smart susceptor heater blanket and the first working surface, and the second protective release layer is the second smart susceptor heater blanket and the second working surface. The heater blanket deployment system according to Clause 10, which is placed between.
Clause 12. A first smart susceptor heater blanket comprises a first wire assembly with a first susceptor wire wound around a first litz wire and a second smart susceptor heater blanket around a second litz wire. The heater blanket deployment system according to Clause 1, comprising a second wire assembly comprising a second wound susceptor wire.
Clause 13. A first wire ribbon comprising a first wire assembly, with a first wire ribbon having a first length from a first connector to a second connector; and a second wire ribbon comprising a second wire assembly. 12. The heater blanket deployment system according to clause 12, further comprising a second wire ribbon having a second length from a third connector to a fourth connector.
Clause 14. The heater blanket deployment system according to Clause 13, wherein the first length varies by less than ± 20% from the second length.
Clause 15. A method for processing a first workpiece and a second workpiece: placing the first workpiece on the first working surface of the first workstation; A first heater blanket assembly with a smart susceptor heater blanket, a second smart susceptor heater blanket, and a first vacuum bag, from a first position away from a first workpiece, a first cover. Moving to a second position close to the work piece; powering the first smart susceptor heater blanket and the second smart susceptor heater blanket to heat the first work piece; The first vacuum bag is evacuated to remove gas from the first work piece; the second work piece is placed on the second working surface of the second workstation. To do; a second heater blanket assembly with a third smart susceptor heater blanket, a fourth smart susceptor heater blanket, and a second vacuum bag is placed in a third position away from the second workpiece. To move from to a fourth position close to the second work piece; power to the third smart susceptor heater blanket and the fourth smart susceptor heater blanket to heat the second work piece. Supplying; including subjecting the second vacuum bag to a second vacuum to remove gas from the second workpiece, the first workstation becomes the second workstation. Positioned adjacently; the power supply of the first smart susceptor heater blanket, the second smart susceptor heater blanket, the third smart susceptor heater blanket, and the fourth smart susceptor heater blanket was supported by the frame. Performed using a power source; a method in which the first and second vacuum bags are evacuated using a vacuum source supported by a frame.
Clause 16. Moving the first mounting surface of the frame attached to the first heater blanket assembly during the movement of the first heater blanket assembly; and moving the second heater during the movement of the second heater blanket assembly. 25. The method of clause 15, further comprising moving a second mounting surface of a frame attached to the blanket assembly.
Clause 17. The frame is first mounted only when the first mounting surface and the first heater blanket assembly of the frame move from the fourth mounting surface to the third position by the second mounting surface and the second heater blanket assembly. 16. The method of clause 16, which is configured to be able to move from position to second position.
Clause 18. The method of clause 17, wherein the second vacuum bag cannot be evacuated while the first vacuum bag is evacuated.
Clause 19. The frame moves from the first position to the second position where the first mounting surface and the first heater blanket assembly of the frame move from the first position to the second position regardless of the movement of the second mounting surface and the second heater blanket assembly. The method according to clause 16, which is configured to be capable.
Clause 20. The first workpiece comprises a plurality of first uncured composite plies; the second workpiece comprises a plurality of second uncured composite plies; the first vacuum bag is evacuated. The method of clause 15, further comprising devaluing the first workpiece in between and devaluing the second workpiece while vacuuming the second vacuum bag.

Despite the approximate numerical ranges and parameters that specify the broad disclosure, the values specified in the particular example are reported as accurately as possible. However, any number essentially contains some error that inevitably arises from the standard deviation found in each test measurement. Further, it should be understood that all the scopes disclosed herein include all subranges contained herein. For example, a range of "less than 10" can include any subrange (including them) between a minimum of 0 and a maximum of 10, in short, any subrange can be, for example, 1. It has a minimum value of 0 or more and a maximum value of 10 or less, such as from 5. In some cases, the numbers presented as parameters can take negative values. In this case, the illustrated range described as "less than 10" can assume negative values such as -1, -2, -3, -10, -20, -30.

Although this teaching has been exemplified with respect to one or more embodiments, modifications and / or modifications may be made to the examples shown without departing from the gist and scope of the appended claims. For example, it will be appreciated that the process is described as a series of actions or events, but the disclosure is not limited to the order of such actions or events. Such actions may occur in a different order and / or at the same time as another action or event other than those described herein. Also, not all process steps are required to implement the methodology in accordance with one or more aspects or embodiments of the present disclosure. It will be recognized that structural components and / or processing steps can be added and existing structural components and / or processing stages can be removed or modified. Moreover, one or more of the actions presented herein may be performed in one or more separate actions and / or stages. Furthermore, the terms "inclusion", "includes", "having", "has", "with" or their variants are detailed explanations and patents. As far as it is used in both claims, such terms are intended to be included as well as the term "comprising". The term "at least one of" is used to mean that one or more of the listed items can be selected. As used herein, for example, the term "one or more" with respect to enumerating items such as A and B means only A, only B, or A and B. The term "at least one" is used to mean that one or more of the listed items can be selected. Further, within the scope of the discussion and claims, the term "on" used for two materials, such as one on the other, means at least some contact between the materials. "Over" may involve one or more additional intervening materials that are close to each other but are accessible but not essential. Neither "on" nor "over" indicates any direction as used herein. The term "isometric" refers to a coating material in which the angle of the underlying material is protected by the isometric material. The term "about" indicates that the listed values may change somewhat as long as they do not cause a process or structural incompatibility with the illustrated embodiments. Finally, "exemplary" indicates that the description is used as an example rather than suggesting that it is ideal. Other embodiments of the present disclosure will become apparent to those skilled in the art by reviewing the specifications and practices of the disclosure herein. The specifications and examples are intended to be considered merely exemplary, and the true scope and gist of the present disclosure is set forth by the following claims.

The term relative position used in this application is defined based on the conventional plane of the work piece or the plane parallel to the work plane, regardless of the orientation of the work piece. As used in this application, the terms "horizontal" or "lateral" are parallel to the conventional plane or working surface of the work piece, regardless of the orientation of the work piece. Defined as a plane. The term "vertical" refers to the direction perpendicular to the horizontal. Terms such as "on", "side (as in" side wall ")", "high", "low", "over", "top", "below" It is defined for a conventional plane or work surface on the top surface of the work piece, regardless of the orientation of the work piece.

Claims (14)

Heater blanket deployment system (1700, 1900, 2000)
The first workstation (1702A, 1902A, 2006A)
A first heater blanket comprising a first smart susceptor heater blanket (300) and a second smart susceptor heater blanket (300') positioned adjacent to the first smart susceptor heater blanket (300). Assemblies (1704A, 1904A, 2004A) and
During the processing of the first workpiece (1712A), the first smart susceptor heater blanket (300) and the second smart susceptor heater blanket (300') cover the first working surface (1710A). A first workstation (1702A, 1902A, 2006A) comprising a first working surface (1710A) configured to be configured.
The second workstation (1702B, 1902B, 2006B)
A second heater blanket comprising a third smart susceptor heater blanket (300) and a fourth smart susceptor heater blanket (300') positioned adjacent to the third smart susceptor heater blanket (300). Assemblies (1704B, 1904B, 2004B) and
During the processing of the second workpiece (1712B), the third smart susceptor heater blanket (300) and the fourth smart susceptor heater blanket (300') cover the second working surface (1710B). A second workstation (1702B, 1902B, 2006B) with a second working surface (1710B) configured to be configured.
A frame (1216) supporting the first heater blanket assembly (1704A, 1904A, 2004A) and the second heater blanket assembly (1704B, 1904B, 2004B).
At least one power source (502) configured to power the first workstations (1702A, 1902A, 2006A) and the second workstations (1702B, 1902B, 2006B) from the frame (1216). ), A heater blanket deployment system (1700, 1900, 2000). The frame (1216) moves the first heater blanket assembly (1704A, 1904A, 2004A) towards and away from the first working surface (1710A). Further, the second heater blanket assembly (1704B, 1904B, 2004B) is moved toward the second working surface (1710B) and away from the second working surface (1710B). The heater blanket deployment system according to claim 1 (1700, 1900, 2000), which is configured to be capable of. A first mounting surface (1706A, 1906A) in which the frame (1216) is coupled to the first heater blanket assembly (1704A, 1904A, 2004A) and the second heater blanket assembly (1704B, 1904B, 2004B). The heater blanket deployment system (1700, 1900, 2000) according to claim 2, further comprising a second mounting surface (1706B, 1906B) coupled to the). The first workpiece (1712A) is the first workstation (1712A) only when the second workpiece (1712B) in the second workstation (1702B, 1902B, 2006B) has not been processed. The heater blanket deployment system (1700, 1900, 2000) of claim 3, which is configured to be capable of processing in 1702A, 1902A, 2006A). A base (1716) mechanically connected to the first mounting surface (1706A, 1906A) and the second mounting surface (1706B, 1906B) is further provided with the first mounting surface (1706A, 1906A). The heater blanket deployment system (1700, 1900, 2000) according to claim 3 or 4, wherein the second mounting surface (1706B, 1906B) and the base (1716) form a Y-shaped frame. The frame (1216) lowers the first heater blanket assembly (1704A, 1904A, 2004A) towards the first working surface (1710) and separates from the first working surface (1710). As described above, the first heater blanket assembly (1704A, 1904A, 2004A) is configured to be raised, and the second heater blanket assembly (1704B, 1904B, 2004B) is further directed toward the second working surface (1710B). ) Lower and away from the second working surface (1710B). Overhead with a plurality of winches (2016) configured to raise the second heater blanket assembly (1704B, 1904B, 2004B). The heater blanket deployment system (1700, 1900, 2000) according to any one of claims 1 to 5, which is a frame (2010). The plurality of lifting straps (2018) attached to one of the first heater blanket assembly (1704A, 1904A, 2004A) and the second heater blanket assembly (1704B, 1904B, 2004B) are further provided. The winch (2016) uses the plurality of lifting straps (2018) to lower the first heater blanket assembly (1704A, 1904A, 2004A) towards the first working surface (1710). And configured to raise the first heater blanket assembly (1704A, 1904A, 2004A) away from the first working surface (1710), and further using the plurality of lifting straps (2018). The second heater so as to lower the second heater blanket assembly (1704B, 1904B, 2004B) towards the second working surface (1710B) and away from the second working surface (1710B). The heater blanket deployment system (1700, 1900, 2000) according to claim 6, which is configured to raise the blanket assembly (1704B, 1904B, 2004B). The first workstation (1702A, 1902A, 2006A) further comprises a first vacuum bag (1114A).
Before SL as the first vacuum bag (1114A) covers said first working surface (1710A) during processing of the first workpiece (1712a), the first work station (1702A, 1902A, 2006A) is configured and
The second workstation (1702B, 1902B, 2006B) further comprises a second vacuum bag (1114B).
Before SL as the second vacuum bag (1114B) covers said second working surface during processing of the second workpiece (1712B) (1710B), the second work station (1702B, 1902B, 2006B) is configured and
A base (1716, 1904, 2011) in which the frame (1216) is placed directly between the first workstation (1702A, 1902A, 2006A) and the second workstation (1702B, 1902B, 2006B). With more
The heater blanket deployment system (1700, 1900, 2000) further comprises a vacuum supply device (1008) for fluid communication with the first vacuum bag (1114A) and the second vacuum bag (1114B).
Any one of claims 1 to 7, wherein the at least one power source (502) and the vacuum supply device (1008) are located within the base (1716, 1904, 2011) of the frame (1216). The heater blanket deployment system according to (1700, 1900, 2000). At least a first elongated seal (1408) configured to maintain a first vacuum between the first heater blanket assembly (1704A, 1904A, 2004A) and the first working surface, and the first. Claimed to further include at least a second elongated seal (1408) configured to maintain a second vacuum between the heater blanket assembly of 2 (1704B, 1904B, 2004B) and the second working surface. Item 8. The heater blanket deployment system (1700, 1900, 2000). The first protective release layer (1106A) covering the first smart susceptor heater blanket (300) and the second smart susceptor heater blanket (300'), the third smart susceptor heater blanket (300), and the above. The heater blanket deployment system (1700, 1900, 2000) according to any one of claims 1 to 9, further comprising a second protective release layer (1106B) covering a fourth smart susceptor heater blanket (300'). ). A method for processing a first workpiece (1712A) and a second workpiece (1712B).
Placing the first workpiece (1712A) on the first working surface of the first workstation (1702A, 1902A, 2006A) (2102) and
A first heater blanket assembly (1704A, 1904A, 2004A) comprising a first smart susceptor heater blanket (300), a second smart susceptor heater blanket (300'), and a first vacuum bag (1114A). Moving from a first position away from the first workpiece (1712A) to a second position closer to the first workpiece (1712A) (2104).
Powering the first smart susceptor heater blanket (300) and the second smart susceptor heater blanket (300') to heat the first workpiece (1712A) (2106).
In order to remove gas from the first workpiece (1712A), the first vacuum bag (1114A) is first evacuated (2108).
Placing the second workpiece (1712B) on the second working surface of the second workstation (1702B, 1902B, 2006B) (2110) and
A second heater blanket assembly (1704B, 1904B, 2004B) comprising a third smart susceptor heater blanket (300), a fourth smart susceptor heater blanket (300'), and a second vacuum bag (1114B). Moving from a third position away from the second work piece (1712B) to a fourth position closer to the second work piece (1712B) (2112).
Powering the third smart susceptor heater blanket (300) and the fourth smart susceptor heater blanket (300') to heat the second workpiece (1712B) (2114).
The second vacuum bag (1114B) is subjected to a second vacuum treatment (2116) in order to remove gas from the second workpiece (1712B).
The first workstation (1702A, 1902A, 2006A) is positioned adjacent to the second workstation (1702B, 1902B, 2006B).
The first smart susceptor heater blanket (300), the second smart susceptor heater blanket (300'), the third smart susceptor heater blanket (300), and the fourth smart susceptor heater blanket (300'). power supplying (2106,2114) is performed using a supported power (502) by a frame (1216), the
Evacuating the first vacuum bag (1114A) and the second vacuum bag (1114B) (2108, 2116) using a vacuum source (1408) supported by the frame (1216). How to be executed. The first mounting surface (1216) of the frame (1216) attached to the first heater blanket assembly (1704A, 1904A, 2004A) while the first heater blanket assembly (1704A, 1904A, 2004A) is moving. 1706A, 1906A) and
The second mounting surface of the frame (1216) attached to the second heater blanket assembly (1704B, 1904B, 2004B) during the movement of the second heater blanket assembly (1704B, 1904B, 2004B). 11. The method of claim 11, further comprising moving (1706B, 1906B). Said first mounting surface before SL frame (1216) (1706A, 1906A) and said first heater blanket assembly (1704A, 1904A, 2004A) said second mounting surface (1706B, 1906B) and the second Claim that the frame (1216) is configured so that it can move from the first position to the second position independently of the movement of the heater blanket assemblies (1704B, 1904B, 2004B). 12. The method according to 12. The first workpiece (1712A) comprises a plurality of first uncured composite plies (1400).
The second workpiece (1712B) comprises a plurality of second uncured composite plies (1400).
While devaluing the first workpiece (1712A) while performing the vacuum treatment on the first vacuum bag (1114A) and performing the vacuum treatment on the second vacuum bag (1114B). The method according to any one of claims 11 to 13, further comprising devalking the second workpiece (1712B).

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